The Influences of Grain Refiner, Inclusion Level, and Filter Grade on the Filtration Performance of Aluminum Melt

Yang, Jiawei; Bao, Sarina; Akhtar, Saleem; Tundal, Ulf; Tjøtta, Stig; Li, Yanjun

doi:10.1007/s11663-021-02310-7

Cited by 5 publications

(4 citation statements)

References 30 publications

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“…In both our own research (Figure 10) and that of others [6,27], borides have been found to inhibit the flow of liquid metal through the Prefil Footprinter ® filter. According to the authors of Yang et al [28], the reduction in efficiency is due to the strong adherence of TiB 2 particles to oxide films in the filter. The adherence and agglomeration of heavy grain refiner particles onto oxide films counter the gravitation number of oxide films, making them difficult to be filtrated [28].…”

Section: Discussionmentioning

confidence: 99%

“…According to the authors of Yang et al [28], the reduction in efficiency is due to the strong adherence of TiB 2 particles to oxide films in the filter. The adherence and agglomeration of heavy grain refiner particles onto oxide films counter the gravitation number of oxide films, making them difficult to be filtrated [28]. This can also lead to the inhibition of the filtration process during alloy casting.…”

Section: Discussionmentioning

confidence: 99%

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Analysis of Inclusions and Impurities Present in Typical HPDC, Stamping and Extrusion Alloys Produced with Different Scrap Levels

da Silva,

Pujante,

Hrabia-Wiśnios

et al. 2024

Metals

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The European Green Deal poses a two-pronged challenge for the automotive industry: migrating to solutions based on light structures, requiring lightweight concepts and light materials, while at the same time avoiding dependence on the importation of these advanced materials. Aluminium alloys are lightweight and cost-effective materials that can successfully meet the requirements of many structural applications; however, their production requires bauxite and other Critical Raw Materials (CRMs), such as Si and Mg. Aluminium alloys are fully recyclable, but scrap is usually contaminated and its use is related to an increment of impurities, tramp elements and undesired inclusions. Traditionally, the use of secondary alloys has been restricted to low-performance applications. The present work analyses the effect that the use of scrap has on the quantity of inclusions present in the alloy and on other properties relevant for material processing. This study was carried out using common alloys associated with three of the most common aluminium processes used in the car manufacturing industry: high-pressure die casting (HPDC) (AB-43500), extrusion (6063) and sheet metal forming (5754 and 6181). The reference alloys were mixed with different levels of scrap (0, 20, 40, 60, 80 and 100%), with an aim to keep the chemical composition as unaffected as possible. The inclusion level of the alloy was characterized using the Prefil Footprinter® test. In addition, the obtained materials, after being cast in an open mould, were subjected to metallographic characterization. Relevant properties were measured to assess the processability of the alloys for the corresponding transforming process using the flowability test for the HPDC alloy and high-temperature compression for the extrusion alloys. The results obtained suggest that the number of inclusions present in the melt highly increase with the amount of scrap used to produce the alloy. These inclusions are also related to a significant loss of flowability, but do not have a noticeable impact on microstructure.

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Section: Discussionmentioning

confidence: 99%

Section: Discussionmentioning

confidence: 99%

Analysis of Inclusions and Impurities Present in Typical HPDC, Stamping and Extrusion Alloys Produced with Different Scrap Levels

da Silva,

Pujante,

Hrabia-Wiśnios

et al. 2024

Metals

View full text Add to dashboard Cite

show abstract

“…In both our own research (Figure 10) and that of others [23,24], borides have been found to inhibit the flow of liquid metal through the Prefil Footprinter ® filter. According to the authors of Yang et al [25] the reduction of efficiency is due to the strong adherence of TiB2 particles to oxide films in the filter. The adherence and agglomeration of heavy grain refiner particles onto light oxide films counter the gravitation number of oxide films, making them difficult to be filtrated [25].…”

Section: Discussionmentioning

confidence: 99%

“…According to the authors of Yang et al [25] the reduction of efficiency is due to the strong adherence of TiB2 particles to oxide films in the filter. The adherence and agglomeration of heavy grain refiner particles onto light oxide films counter the gravitation number of oxide films, making them difficult to be filtrated [25]. This can also lead to inhibition of the filtration process during alloy casting.…”

Section: Discussionmentioning

confidence: 99%

Analysis of Inclusions and Impurities Present in Typical Hpdc, Stamping and Extrusion Alloys Produced with Different Scrap Levels

Da Silva,

Pujante,

Hrabia-Wisnios

et al. 2024

Preprint

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The European Green Deal poses a two-pronged challenge for the automotive industry: migrating to solutions based in light structures, requiring light weight concepts and light materials, while at the same time avoiding dependence towards the importation of these advanced materials. Aluminium alloys are lightweight and cost-effective materials that can successfully cover the requirements of many structural applications, however their production requires from bauxite and other Critical Raw Materials (CRM), such as Si and Mg. Aluminium alloys are fully recyclable, but scrap is usually contaminated and its use is related to an increment of impurities, tramp element and undesired inclusions. Traditionally, the use of secondary alloys has been restricted to low performance applications. The present work analyses the effect that the use of scrap has in the quantity of inclusions present in the alloy and in other properties relevant for the material processing. The study was carried out for common alloys belonging to 3 of the most common aluminium processes used in the car manufacturing industry: High Pressure Die Casting (HPDC) (EN AC-43500), extrusion (6063) and sheet metal forming (5754 and 6181). Reference alloy were mixed with different level of scrap (0, 20, 40, 60, 80 and 100%) trying to keep the chemical composition as unaffected as possible. The inclusions level of the alloy was characterized with the Prefil Foot-printer® test. In addition, the obtained materials, after being cast in an open mould, were subjected to metallographic characterization. Relevant properties to assess the formability quality of the alloys for the corresponding transforming process, were obtained: flowability test for HPDC alloy and high temperature compression for extrusion alloys. The results obtained suggest that the number of inclusions present in the melt highly increase with the amount of scrap used to produce the alloy. These inclusions are also related with an important lost of flowability, but do not have a noticeable impact on microstructure.

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Effect of Inclusion and Filtration on Grain Refinement Efficiency of Aluminum Alloy

Yang

Bao

et al. 2022

Metall Mater Trans A

Self Cite

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It is well known that the filtration efficiency of ceramic foam filters (CFF) on aluminum melt can be significantly reduced by the addition of grain refiner particles under a high inclusion load. Also, it is usually considered that the filtration process has little impact on grain refinement efficiency. In this work, the influence of inclusions and filtration on the grain refinement effect of AA 6060 alloy has been studied. This was done through TP-1 type solidification experiments where the aluminum melt prior to and after the filter during a pilot-scale filtration test was investigated. In the experiments, 80 PPi CFFs were used to filtrate aluminum melt with an ultra-high inclusion load and two addition levels of Al–3Ti–1B master alloys. It is found that both inclusions and filtration significantly reduce the grain refinement efficiency of the grain refiner master alloys. A detailed characterization of the used filters shows that the reduction of grain refinement efficiency is due to the strong adherence of TiB2 particles to the oxide films, which are blocked by the CFF during filtration. A grain size prediction model based on deterministic nucleation mechanisms and dendritic growth kinetics has been applied to calculate the solidification grain size and estimate the loss of effective grain refiner particles during filtration. It is shown that due to the strong adherence between TiB2 particles and oxide films in the melt, the high addition level of aluminum chips also has an influence on reducing the grain refinement efficiency of aluminum melt without filtration. The results of this study extended our understanding of the behavior and performance of inoculant particles in CFF and their interactions with the inclusions.

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The Influences of Grain Refiner, Inclusion Level, and Filter Grade on the Filtration Performance of Aluminum Melt

Cited by 5 publications

References 30 publications

Analysis of Inclusions and Impurities Present in Typical HPDC, Stamping and Extrusion Alloys Produced with Different Scrap Levels

Analysis of Inclusions and Impurities Present in Typical HPDC, Stamping and Extrusion Alloys Produced with Different Scrap Levels

Analysis of Inclusions and Impurities Present in Typical Hpdc, Stamping and Extrusion Alloys Produced with Different Scrap Levels

Effect of Inclusion and Filtration on Grain Refinement Efficiency of Aluminum Alloy

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